Cushioning material



Jan. 16, 1968 R T MCCLWE 3,363,270

CUSHIONING MATERIAL Filed July 19, 1966 Q/ 742 71 70278 @a 7g W' 74? 7 gy g g Y* JNVENTQR.

TTOFNEYS United States Patent 3,363,270 CUSHINING MATERIAL Ralph T. McClive, 8S Knowlton Ave., Kenmore, N.Y. 14217 Filed July 19, 1966, Ser. No. 566,279 3 Claims. (Cl. 5-345) ABSTRACT OF THE DISCLOSURE This invention relates to cushions or padding made up of two materials, one of which is less resilient than the other and is covered on all faces and edges yby the more resilent material, which is provided with grooves or recesses at the folds and which permit the outer material to -be folded through approximately right angles to provide a cushion or padding which is free from -bulges or enlargements adjacent to the folds.

In the accompanying drawings:

FIG. 1 is a perspective view of a cushion or padding embodying this invention.

FIG. 2 is an inside face view of the outer material of the cushion showing its construction prior to folding the same around the inner layer.

FIGS. 3 and 4 are respectively transverse sectional views of the cushion.

FIG. 5 is a partial perspective view of a cushion having an outer layer of slightly modified construction.

There are a number of materials that may be used in connection with the making of a cushion or padding of this type. The inner layer may be made of a material which of itself is not sufficiently resilent or flexible to form by itself a comfortable cushion or padding, but is desirable because of its tendency to retain its shape. The inner layer, for example, may be made of a cellulose fiber, felted cotton in batt form or garnetted, fiberglass, bonded polyurethane, or other materials of a like nature. Cushions made of these materials alone are not cornfortable to sit on or to lean against since they appear to be hard and do not provide restful supports. Consequently, it is desirable to cover the inner layer with a softer material, such for example, as a cellular polyurethane of medium to firm density and which can be compressed so that the opposite faces of a sheet of about two inches in thickness nearly come together when moderate pressure is applied. Consequently this material by itself, if made into a cushion pad, does not form an adequate support so that a person sitting or leaning against a cushion made entirely of this material receives very little cushioning effect since it is readily compressed so that it has no more resiliency. However, the two materials comprising the inner layer entirely enclosed in the polyurethane material form an ideal cushion or pad, since the initial weight or pressure applied to it is taken up by the outer layer or layers of polyurethane, and the final cushioning effect is then produced mainly by the inner layer.

It is important in this connection to combine the materials in such a manner ras to produce a satisfactory final product of neat appearance and having the parts thereof rmly secured together so as to prevent breakage and so that the outer layer extends completely around the inner layer to support the same against damage from continued use. Also the inner layer holds the outer layer in correct position against folding or creasing. For most padding purposes, for example, in connection with the manufacture of upholstered or padded furniture and for use in seat cushions in automobiles or the like, it is desirable that the cellular polyurethane product forming the outer material be of considerable thickness to prom@ Patented Jan. 16, 1968 ICC duce the desired cushioning eiTect in combination With the inner layer, and it is consequently desirable to make this outer cushioning material of considerable thickness. This of course interferes with the smooth Wrapping of the outer layer around the inner layer, since the outer layer will then bulge at the corners or edges about which it is bent. In order to prevent this from occurring, I have provided the outer layer or the inner face thereof with grooves cut into the same at the portions which are to be bent or folded. For example, if the outer layer 7 is to be bent to cover the two opposite faces and also the edge portions of the cushion, I provide the material of the outer layer with V-shaped grooves extending lengthwise of the cushion. The grooves extend into the material fairly close to the outer face of this material and are preferably such as to form angles of approximately degrees between the sides of the groove so that when the outer layer is folded at the edges of the inner layer 10, as shown in FIGS. 3 and 4, the two sides of each of the grooves come into contact with each other and thus greatly facilitate the folding of the material around the inner layer 10, since the actual folding of the material takes place at the thin parts at the bottoms of the grooves. The outer layer may then be folded around the inner layer and the two ends of the outer layer can be brought together and suitably secured to each other. Preferably to improve the appearance and eciency of the final product, the two edges 12 of the outer layer are brought into contact with each other at a portion of either face of the cushion spaced from the corners, and these edges 12 `are then suitably cemented or otherwise secured to each other. There will consequently be no seam of increased thickness at the junction of the two edges.

lf it is desired to extend the same material around the end portions of the inner layer 10, I provide grooves 14 extending crosswise of the outer layer and the grooves 8 so that the two portions 15 of the outer layer extending beyond the grooves 14 can be readily bent through approximately 90 degrees and meet at the ends of the 'inner layer 10 in spaced relation to the bent edges Where these ends of the material may be cemented or otherwise secured together. In order to fit into the edges of the parts which have already been bent around the inner layer 10, I provide inclined edges 17 and 18 which permit .the portions 15 to form correct corners with the parts of the outer layer which have already been positioned about the inner layer 1t), as shown in FIG. 1.

It is also possible to make a cushion of this type without having the ends of the cushion covered, as shown in FIGS. 1, 2 and 4. This can be readily done as shown in FIG. 5, by having the opposite ends of the outer layer cut square at the ends of the inner layer 10 so that the ends 21 of the outer layer may be secured together with a separate end piece 22 cemented at the four surfaces to the end edges of the outer member 7.

It will be understood that various changes in the details, materials and arrangements of parts which have been herein described and illustrated in order to explain the nature of the invention may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims.

I claim:

1. A cushion comprising an inner layer of a less flexible cushioning material and an outer layer of a more flexible cushioning material in sheet form extending about the opposite faces and edges of said inner layer, said layers being of approximately the same thickness and in which the outer layer has its folded edges formed by providing at the lines of fold V-shaped notches formed to extend inwardly from the inner surface of a layer into approximately the outer surface but not through said outer surface, said outer layer when folded having the two sides of the V-shaped notches lying in contact to form on the exterior of the cushion substantially sharp 90 degree bends.

2. A cushion according to claim 1 and having the edges of said outer layer coming together in spaced Ielation to said bends, and means for securing together said edges.

3. A cushion according to claim 1 in which said outer layer Where folded is provided at the lines of fold with V-shaped notches on the inner surface of said layer with the sides of the V-shaped notches lying in Contact to form relatively sharp bends at said fold.

CASMIR A. 15

References Cited UNITED STATES PATENTS FOREIGN PATENTS Belgium. Great Britain.

NUNBERG, Primary Examiner. 

